Horizontal integration tooling for launch vehicles, and associated systems and methods

ABSTRACT

A representative system includes an alignment tool for aligning attachment interfaces of horizontally-oriented launch vehicle portions. The tool can include a receiver assembly for connecting to a first launch vehicle portion and an actuation assembly for connecting to a second launch vehicle portion. When a first connecting element of the receiver assembly is engaged with a second connecting element of the actuation assembly, the second connecting element can apply force to the receiver assembly, and the actuator assembly applies an opposite force to the second launch vehicle portion, to align fastening features in the launch vehicle portions and/or to reshape the launch vehicle portions. A representative method includes connecting the alignment tool to the launch vehicle portions and operating the tool to apply oppositely-directed forces to align the launch vehicle portions for installing fasteners to connect the launch vehicle portions. One or more bracing beams can connect two tools together.

TECHNICAL FIELD

The present disclosure is directed generally to horizontal integrationtooling for launch vehicles, and associated systems and methods.Representative aspects of the present disclosure include an alignmenttool for aligning attachment interfaces of horizontally-oriented rocketsections. More generally, aspects of the technology relate to alignmentsystems and methods for integrating cylindrical or tubular structures.

BACKGROUND

Launch vehicles and other rocket systems are traditionally assembled ator near a launch site from multiple component sections. For example,two, three, or even more cylindrical sections can be attached togetherto form a cylindrical launch vehicle body. Some launch vehicle systemsare assembled vertically by stacking the component sections on top ofother component sections. For large launch vehicles made with severalcomponent sections, vertical assembly can be challenging as the heightof the launch vehicle body can require tall assembly buildings andequipment. Accordingly, horizontal integration may be preferable forsome launch vehicles. Component sections may be oriented horizontallyand assembled at ground level.

One challenge associated with horizontal integration is the tendency forcomponent sections to sag and deflect out of their intended shapes dueto gravity. For example, a circular section may deflect toward an ovalshape. Sag and deflection can hinder connection of component sections bycausing misalignment of fastening features. Aspects of the presentdisclosure are directed to addressing this challenge.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the sameelement throughout the views:

FIG. 1 is a partially schematic perspective view of twohorizontally-oriented launch vehicle portions being brought together forintegration.

FIG. 2 is a schematic diagram of the sag and/or deflection of a launchvehicle portion (such as one of the portions illustrated in FIG. 1 ) asa result of being horizontally-oriented.

FIGS. 3A and 3B illustrate schematic diagrams of an alignment strategyfor rounding or de-ovalizing the launch vehicle portions to align boltholes or other fastening features.

FIG. 4 illustrates a partially schematic side cross-sectional view of aportion of the mating interface between the launch vehicle portions, inaccordance with some embodiments of the present technology.

FIG. 5 is a side schematic view of an alignment tool configured inaccordance with embodiments of the present technology, positioned toalign the launch vehicle portions for integration together. Thealignment tool includes an actuation assembly and a receiver assembly.

FIG. 6 is a partially schematic perspective view of an actuationassembly configured in accordance with embodiments of the presenttechnology.

FIG. 7 is a partially schematic perspective view of a receiver assemblyconfigured in accordance with embodiments of the present technology.

FIG. 8 is a partially schematic perspective view of the mating interfacebetween the first launch vehicle portion and the second launch vehicleportion, with multiple alignment tools positioned to align the portionsin accordance with some embodiments of the present technology.

FIG. 9 is a schematic illustration of a distribution of alignment toolsand bracing beams connecting some of the alignment tools around theperimeter of a mating interface between launch vehicle portions, inaccordance with embodiments of the present technology.

FIG. 10 is a flow chart illustrating a method of aligning and fasteningtogether two launch vehicle portions.

DETAILED DESCRIPTION

Embodiments of the technology disclosed herein are directed generally toalignment systems and methods for integrating cylindrical or tubularstructures. Several embodiments of the present technology are directedto alignment tools for aligning fastener holes in launch vehicleportions, but the present technology can generally be used to connecttubular structures other than launch vehicle portions.

A representative method of aligning and fastening a first launch vehicleportion to a second launch vehicle portion includes connecting areceiver assembly to the first launch vehicle portion, connecting anactuation assembly to the second launch vehicle portion, establishingcontact between the receiver assembly and the actuation assembly, andoperating the actuation assembly to apply oppositely-directed forces tothe receiver assembly and to the second launch vehicle portion, until afirst fastener hole in the first launch vehicle portion aligns with asecond fastener hole in the second launch vehicle portion.

Connecting the receiver assembly to the first launch vehicle portion caninclude positioning a first peg in a first fastener hole in the firstlaunch vehicle portion. Connecting the actuation assembly to the secondlaunch vehicle portion can include positioning a second peg in a secondfastener hole in the second launch vehicle portion. Establishing contactbetween the receiver assembly and the actuation assembly can includeengaging a first connecting element carried by the receiver assemblywith a second connecting element carried by the actuation assembly.Other representative methods include connecting a second receiverassembly to the first launch vehicle portion, connecting a secondactuation assembly to the second launch vehicle portion, andestablishing contact between the second receiver assembly and the secondactuation assembly. Further representative methods include connectingthe first receiver assembly to the second receiver assembly and/orconnecting the first actuation assembly to the second actuationassembly, via one or more bracing beams.

A representative system for aligning first fastener holes in a firsttubular structure (such as a first launch vehicle portion) with secondfastener holes in a second tubular structure (such as a second launchvehicle portion) includes an alignment tool having a receiver assemblyand an actuation assembly. The receiver assembly can include a firstchassis, a first peg attached to the first chassis and configured to bepositioned in one of the first fastener holes, and a first connectingelement attached to the first chassis. The actuation assembly caninclude a second chassis, a second peg attached to the second chassisand configured to be positioned in one of the second fastener holes, anda second connecting element movably attached to the second chassis. Thefirst connecting element and the second connecting element arepositioned and configured to engage one another, such that when thefirst connecting element is engaged with the second connecting elementand the second connecting element is moved relative to the secondchassis, the actuation assembly applies a first force to the receiverassembly and a second force to the second tubular structure that isopposite the first force, to align one or more fastening features in thetubular structures and/or to de-ovalize, round, or reshape the tubularstructures.

Several details describing structures and processes that are well-knownand often associated with launch vehicles are not set forth in thefollowing description to avoid obscuring other aspects of thedisclosure. Moreover, although the following disclosure sets forthseveral embodiments, several other embodiments can have configurations,arrangements, and/or components that are different than those describedin this section. In particular, other embodiments may have additionalelements, and/or may lack one or more of the elements described belowwith reference to FIGS. 1-10 .

FIG. 1 is a partially schematic perspective view of twohorizontally-oriented launch vehicle portions (which may also bereferred to as rocket sections) being brought together for integration.A first portion 100 may be fixed in a support 110. A movable platform120 can carry a second portion 130 and can manipulate the second portion130 into position adjacent to the first portion 100 to mate or integratethe two portions 100, 130. Accordingly, the movable platform 120 canmove the first and/or second portions 100, 130 relative to each otheruntil they are properly aligned for connection.

In some embodiments, the movable platform 120 provides multiple degreesof freedom of movement of the second portion 130 (e.g., six degrees offreedom). For example, the movable platform 120 can move along thehorizontal x- and/or y-axes using wheels or tracks. The movable platform120 can include a jack structure 140 that provides vertical movementalong the z-axis. The jack structure 140 can optionally move the secondportion 130 along the x-axis and/or y-axis relative to the remainder ofthe movable platform 120. The jack structure 140 can also rotate thesecond portion 130 about a horizontal axis x1 (which can be the centralaxis of the second portion 130) by rotating a removable frame orrotation ring 150 attached to the second portion 130. In someembodiments, the jack structure 140 can tilt the second portion 130 (forexample, about an axis parallel to the y-axis). The movable platform 120(including the jack structure 140) can position the second portion 130to abut the first portion 100, so that the first portion 100 and thesecond portion 130 can be integrated together at a mating interface 160.The portions 100, 130 can be bolted, welded, or otherwise attachedtogether. In particular representative embodiments, the portions 100,130 are bolted together after being aligned and rounded or de-ovalized,as described in additional detail below.

FIG. 2 is a schematic diagram of the sag and/or deflection of a launchvehicle portion (such as one of the portions 100, 130 illustrated inFIG. 1 ) as a result of being horizontally-oriented. Gravity (indicatedby arrow g) tends to pull downwardly on a top section of the launchvehicle portion 100, 130 while the bottom section is supported, causingthe portions to deviate from the nominal shape 200. For example, acircular portion may deflect (e.g., by an amount d) towards an ovalshape, or an oval shape may deflect to an even more oblong shape. Aconsequence of the deflection d is that bolt holes or other fasteningfeatures in the mating portions 100, 130 may not align, which frustratesthe horizontal integration process.

FIGS. 3A and 3B illustrate schematic diagrams of an alignment strategyfor rounding or de-ovalizing the launch vehicle portions 100, 130 toalign bolt holes or other fastening features. FIG. 3A shows the portions100, 130 misaligned (e.g., due to sagging/deflecting under gravity).FIG. 3B shows the portions 100, 130 in alignment after correspondingopposing forces F1 and F2 (e.g., radially inward and outward forces)have been applied to the portions 100, 130. The opposing forces F1, F2cause the launch vehicle portions 100, 130 to align, thereby alsocausing the bolt holes and/or other fastening features to align.Fastener centerlines 300, 310 are shown schematically in FIGS. 3A and 3Bto illustrate the need for, and subsequent provision of, aligning thebolt holes so that the portions 100, 130 can be readily brought togetherfor integration. An alignment tool 320 is schematically illustrated inFIGS. 3A and 3B to illustrate a device for providing the forces F1 andF2 to adjust the alignment of the portions 100, 130. Alignment toolsconfigured in accordance with embodiments of the present technology aredescribed in additional detail below.

FIG. 4 illustrates a partially schematic side cross-sectional view of aportion of the mating interface 160 between the launch vehicle portions100, 130, in accordance with some embodiments of the present technology.The first launch vehicle portion 100 can include a suitable quantity offirst fastener holes or first bolt holes 400, and/or other fasteningfeatures, distributed around the perimeter (e.g., the circumference) ofthe launch vehicle portion 100. The second launch vehicle portion 130can include a suitable quantity of corresponding second fastener holesor second bolt holes 405, and/or other fastening features, distributedaround the perimeter (e.g., the circumference) of the launch vehicleportion 130. The bolt holes 400, 405 can be configured to accommodate abolt/fastener that passes through the bolt holes 400, 405 when the boltholes 400, 405 are aligned, to integrate the launch vehicle portions100, 130. In some embodiments, the bolt holes 400, 405 may have axes 410that are parallel to, or nearly parallel to, a longitudinal axis of alaunch vehicle portion 100, 130 (e.g., axis x1 in FIG. 1 ). In such aconfiguration, to provide access to the bolt holes 400, 405 and anybolts therein, one or both of the launch vehicle portions 100, 130 caninclude a radially-inward depression or bathtub region 420 that providesan open space for tooling to reach the bolt holes 400, 405. The boltholes 400, 405 can be positioned in flanges 430 extending radiallyoutwardly from the bathtub region 420.

In some embodiments, forces (e.g., forces F1 and F2 in FIGS. 3A and 3B)can be applied to the bolt holes 400, 405 to move or shape the launchvehicle portions 100, 130 to be round or to have another desired shape,and/or to align the bolt holes 400, 405. As described in further detailbelow, an alignment tool configured in accordance with embodiments ofthe present technology applies the forces to the bolt holes 400, 405 viapegs or other features that engage the bolt holes 400, 405. To protectthe bolt holes 400, 405, in some embodiments, bushings 440 may bepermanently or temporarily positioned in the bolt holes 400, 405. Thebushings 440 may receive the forces to move or align the launch vehicleportions 100, 130. In some embodiments, the bushings 440 may be formedwith a softer metal than the material forming the bolt holes 400, 405,so that the bushings absorb unintended damage from realignment forcesand/or the tooling, and protect the bolt holes 400, 405.

FIG. 5 is a side schematic view of an alignment tool 500 configured inaccordance with embodiments of the present technology, positioned toalign the launch vehicle portions 100, 130 for connection (e.g., viabolts or other fasteners). The alignment tool 500 can include a receiverassembly 505 and an actuation assembly 510. Each of the assemblies 505,510 can include a peg for engaging one of the bolt holes 400, 405 toapply force to the bolt holes. For example, the receiver assembly 505can include a receiver peg 520 for positioning in one of the first boltholes 400 of the first launch vehicle portion 100 and the actuationassembly 510 can include an actuation peg 550 for positioning in one ofthe second bolt holes 405 of the second launch vehicle portion 130.

In operation, the tool 500 applies a first force to the first launchvehicle portion 100 via the receiver peg 520 engaging with the firstbolt hole 400 (e.g., the radially inward force F1), and the tool 500also applies an opposing second force to the second launch vehicleportion 130 via the actuation peg 550 engaging with the second bolt hole405 (e.g., the radially outward force F2). The pegs 520, 550 radiallypush or pull on the bolt holes 400, 405 to move and/or reshape thelaunch vehicle portions 100, 130.

The tool 500 occupies and adjusts (e.g., aligns) one pair of bolt holes400, 405 in the launch vehicle portions 100, 130. Adjustment of the boltholes 400, 405 occupied by the tool 500 can consequently align othercorresponding pairs of bolt holes which are not occupied by the pegs520, 550. For example, FIG. 8 , which is described in further detailbelow, illustrates tools 500 aligning bolt holes that are not occupiedby the pegs 520, 550. When the bolt holes that are not occupied by thepegs 520, 550 are aligned, fasteners can be installed in thoseunoccupied bolt holes. When the fasteners are installed, they hold theircorresponding bolt holes in alignment so that the tool 500 can beremoved to install fasteners where the tool previously was located,and/or the tool 500 can be relocated to another part of the launchvehicle portions 100, 130 in need of alignment.

In FIG. 5 , the pegs 520, 550 are illustrated as having clearanceswithin the bolt holes 400, 405. In some embodiments, such clearances maybe minimized and the pegs 520, 550 may fit in the bolt holes 400, 405with any tolerance suitable for engaging the bolt holes 400, 405. Insome embodiments, the optional bushing 440 (see FIG. 4 ) may bepositioned in a bolt hole 400, 405 and the peg 520, 550 may bepositioned in the bushing 440. The pegs 520, 550 can be cylindrical pegsin some embodiments, or they may have another elongated shape suitablefor engaging the bolt holes 400, 405 and/or the bushings 440.

The illustrated receiver assembly 505 further includes a lockingmechanism 515. The locking mechanism 515 and the receiver peg 520connect the receiver assembly 505 to the first launch vehicle portion100. When the receiver peg 520 is in the bolt hole 400 of the firstportion 100, the locking mechanism 515 can be activated to fix thereceiver assembly 505 to the first portion 100. For example, the lockingmechanism 515 can include a movable shoe 525 positioned to press againstthe first portion 100. To move the movable shoe 525 to press against thefirst portion 100, the locking mechanism 515 can include a pushing rod530 connected to the movable shoe 525. In some embodiments, the lockingmechanism 515 can include a suitable pushing device for moving thepushing rod 530, such as a lever 535 connected to the pushing rod 530with a suitable linkage 540. Collectively, in some embodiments, alockable toggle clamp can include the pushing rod 530, the lever 535,and the linkage 540. Accordingly, in some embodiments, a commercialoff-the-shelf toggle clamp (such as a lockable over-center clamp) may beimplemented to apply force to the movable shoe 525.

FIG. 5 shows the locking mechanism 515 in a deactivated condition. Thelever 535 can move along a pathway generally labeled P1A to applyleverage to the linkage 540 and to therefore move the pushing rod 530and the movable shoe 525 toward the first portion 100 to press themovable shoe 525 against the first portion 100. When the movable shoe525 is pressed against the first portion 100, the force of the shoe 525against the first portion 100 and the force of the receiver peg 520against the bolt hole 400 tends to fix the receiver assembly 505 on thefirst portion 100. In such a configuration, the locking mechanism 515(which may include a commercial off-the-shelf toggle clamp) provides forsafe operation of the tooling/system by locking components in placeprior to operation. To release the locking mechanism, the lever 535 canmove along a pathway generally labeled P1B to move the pushing rod 530and the movable shoe 525 away from the first portion 100, which loosensthe receiver assembly 505 from the first launch vehicle portion 100,allowing the receiver assembly 505 to be removed.

The actuation assembly 510 can connect to the second launch vehicleportion 130 in a manner similar to the connection of the receiverassembly 505 to the first launch vehicle portion 100. For example, theactuation assembly 510 includes a locking mechanism 545. The lockingmechanism 545 of the actuation assembly 510 and the actuation peg 550 ofthe actuation assembly 510 connect the actuation assembly 510 to thesecond launch vehicle portion 130. When the actuation peg 550 is in thebolt hole 405 of the second launch vehicle portion 130, the lockingmechanism 545 can be activated to fix the actuation assembly 510 to thesecond portion 130. The locking mechanism 545 can include a movable shoe555 positioned to press against the second portion 130. A pushing rod530 driven by a suitable pushing device, such as a lever 535 connectedto the pushing rod 530 with a suitable linkage 540, can move the movableshoe 555 in a manner similar to the function of the pushing rod 530,lever 535, and linkage 540 described above with regard to the receiverassembly 505 (e.g., the lever 535 can move along a pathway generallylabeled P2A to move the shoe 555 toward the second portion 130, andalong an opposing pathway P2B to move the shoe away from the secondportion 130). When the movable shoe 555 is pressed against the secondportion 130, the force of the shoe 555 against the second portion 130and the force of the actuation peg 550 against the bolt hole 405 of thesecond portion 130 tends to fix the actuation assembly 510 on the secondportion 130. In such a configuration, the locking mechanism 545 (whichmay include a commercial off-the-shelf toggle clamp) provides for safeoperation of the tooling/system by locking components in place prior tooperation. Moving the lever 535 to release the pressure of the movableshoe 555 against the second portion 130 can release the actuationassembly 510 from the second portion 130.

When the receiver assembly 505 and the actuation assembly 510 are fixedto the first and second launch vehicle portions 100, 130, respectively,the receiver assembly 505 and the actuation assembly 510 can also beengaged with each other at a force interface 560. The force interface560 is a contact area between the receiver assembly 505 and theactuation assembly 510 that facilitates transferring force between thereceiver assembly 505 and the actuation assembly 510. As the actuationassembly 510 drives against the receiver assembly 505, they contact eachother to transfer force. The actuation assembly 510 applies opposingforces to the receiver assembly 505 and to the second launch vehicleportion 130 (via the peg 550 in the bolt hole 405) to move and/orreshape the portions 100, 130 relative to each other. In other words, asa consequence of the forces transferred at the force interface 560, eachof the receiver assembly 505 and the actuation assembly 510 apply forcesto their respective pegs 520, 550, which in turn apply forces to thebolt holes 400, 405 (for example, via shear force(s) transferred fromthe pegs 520, 550 to the bolt holes 400, 405). The actuation assembly510 pushes the receiver assembly 505 along a radial pathway P3 to alignthe bolt holes 400, 405, de-ovalize the launch vehicle portions 100,130, or to otherwise adjust the launch vehicle portions 100, 130 at themating interface 160 to compensate for deflection from beinghorizontally oriented. Forces exchanged between the receiver assembly505 and the actuation assembly 510 include the upward and/or downwardforces F1 and F2 applied to the portions 100, 130 to cause them toalign. Although the forces F1 and F2 are illustrated in FIG. 5 to show adownward (radially inward) force on the first portion 100 and an upward(radially outward) force on the second portion 130, the tool 500 canoperate to provide forces in the opposite directions (reversing F1 andF2), depending on what adjustments of the launch vehicle portions 100,130 are necessary to bring them into alignment.

In some embodiments, each of the actuation assembly 510 and the receiverassembly 505 include a connecting element, such that the connectingelements are configured to engage one another to transfer force betweenthe receiver assembly 505 and the actuation assembly 510 at the forceinterface 560. For example, in some embodiments, the actuation assembly510 includes an actuation nub 565 that is movable relative to theremainder of the actuation assembly 510 to impart a force on thereceiver assembly 505. The receiver assembly 505 can include a socket570 configured and positioned to receive the actuation nub 565 toreceive force from the receiver assembly 505. Accordingly, in someembodiments, the actuation nub 565 and the socket 570 form the forceinterface 560. In some embodiments, the receiver assembly 505 caninclude the actuation nub 565 and the actuation assembly 510 can includethe socket 570. In further embodiments, any suitable connecting elementscan be carried by the receiver assembly 505 and the actuation assembly510 to form the force interface 560, such as various arrangements ofpins and bushings, a chain connection, a locking pin, or other suitablecomponents or mechanisms for forming a contact area where contact can beestablished between the receiver assembly 505 and the actuation assembly510 to transfer force.

The actuation assembly 510 can include a suitable mechanism for movingthe actuation nub 565 relative to the remainder of the actuationassembly 510 to create force at the force interface 560. In a particularrepresentative embodiment, the actuation assembly 510 includes a chassis575 and a mechanism carried by the chassis that moves the actuation nub565 relative to the chassis 575. In some embodiments, the mechanism caninclude a threaded shaft 580 that is rotatable relative to the chassis575. An actuation block 585, which can carry and/or include theactuation nub 565, includes threaded internal components to facilitatetraversal of the actuation block 585 along the threaded shaft 580 whenthe threaded shaft 580 is rotated (in a manner similar to the functionof a lead screw or screw jack mechanism, such that the threaded shaft580 functions as a lead screw and the actuation block 585 functions as alinear bearing). A suitable source of torque rotates the threaded shaft580 to apply force to the actuation block 585 and the actuation nub 565,and consequently, to the receiver assembly 505. In some embodiments, ahand tool 590 can provide the torque on the threaded shaft 580. Forexample, the hand tool 590 can be a wrench for applying torque to aninput shaft 595 connected to the threaded shaft 580.

Rotating the threaded shaft 580 forces the actuation nub 565 to radiallypush or pull the actuation assembly 510 and the receiver assembly 505(along the pathway labeled P3) to bring the launch vehicle portions 100,130 into their desired relative positions (e.g., to align their boltholes 400, 405). The threaded shaft 580 can rotate in two opposingdirections (e.g., clockwise and counter-clockwise) to move the actuationnub 565 in two opposing directions relative to the chassis 575. Thisallows the tool 500 to selectively force the launch vehicle portions100, 130 in opposite directions, depending on what adjustments arenecessary to align the launch vehicle portions 100, 130 and/or theirbolt holes 400, 405, and/or to otherwise reshape the cross-sections ofthe launch vehicle portions 100, 130. In some embodiments, the actuationassembly 510 can include a suitable structure for limiting or preventingrotation of the actuation block 585 when the shaft 580 is rotated. Forexample, in some embodiments, the actuation block 585 is attached to alinear bearing car 597. The chassis 575 can include a rail element 598.The car 597 can move along the rail element 598 while resisting orpreventing rotation of the actuation block 585 relative to the remainderof the actuation assembly 510.

FIG. 6 is a partially schematic perspective view of the actuationassembly 510. In some embodiments, the input shaft 595 can include a hexhead shape for engaging the hand tool 590 (see FIG. 5 ), although infurther embodiments, other shapes may be used for engaging a suitablehand tool. In some embodiments, the actuation assembly 510 can include athrust bearing 600 that facilitates rotating the threaded shaft 580despite increasing axial loads on the threaded shaft 580 duringoperation (i.e., when the actuation nub 565 applies pushing and pullingforces to the receiver assembly 505, see FIG. 5 ). In some embodiments,the actuation assembly 510 can include a torque limiting coupler 610 toconnect the input shaft 595 to the threaded shaft 580. The torquelimiting coupler 610 can limit the loads applied to the force interface560 (see FIG. 5 ) and to the launch vehicle portions 100, 130 to reducerisk of damaging the relevant components. The chassis 575 carries thevarious components of the actuation assembly 510.

FIG. 7 is a partially schematic perspective view of the receiverassembly 505. A chassis 700 carries the components of the receiverassembly 505. In some embodiments, the socket 570 can be formed as anopening between two shear pins 710 carried by the chassis 700 and fixedin place relative to the chassis 700.

FIG. 8 is a partially schematic perspective view of the mating interface160 between the first launch vehicle portion 100 and the second launchvehicle portion 130, with multiple alignment tools 500 positioned toalign the portions 100, 130, in accordance with some embodiments of thepresent technology. In some embodiments, the alignment tools 500 can beused individually. However, in other embodiments, the alignment tools500 can be used in groups of two, three, or more. For example, in someembodiments, two or more alignment tools 500 can be positioned on thelaunch vehicle portions 100, 130 and distributed around the perimeter ofthe launch vehicle portions 100, 130.

Although the alignment tools 500 can be used individually andseparately, in some embodiments, the alignment tools 500 can be rigidlyconnected together with one or more bracing beams 800, 810. For example,a first bracing beam 800 can rigidly connect two adjacent actuationassemblies 510 and a second bracing beam 810 can rigidly connect twoadjacent receiver assemblies 505. The optional bracing beams 800, 810are configured to facilitate shaping (e.g., rounding or circularizing)the launch vehicle portions 100, 130 by forcing the alignment tools 500to be positioned where they align the bolt holes 400, 405 according tothe required shape at the mating interface 160 (e.g., a circular shape).Due to the perspective of FIG. 8 , the bolt holes 405 of the secondlaunch vehicle portion 130 are not visible, but they are understood tobe generally opposite to the bolt holes 400 of the first launch vehicleportion 100 (see FIG. 5 ). The bracing beams 800, 810 also reducerotation of the alignment tools 500 relative to each other and relativeto the launch vehicle portions 100, 130. When the bolt holes 400, 405 ineach of the launch vehicle portions 100, 130 are suitably aligned, theportions 100, 130 can be bolted together, and the tool 500 can be movedto another radial location at the mating interface 160 or removed(thereby exposing the bolt holes 400, 405 where the tools 500 werepreviously positioned, to insert fasteners).

FIG. 9 is a schematic illustration of a distribution of alignment tools500 and bracing beams 800, 810 around the perimeter of the matinginterface 160, in accordance with embodiments of the present technology.In some embodiments, alignment tools 500 and bracing beams 800, 810 aredistributed around the entire perimeter of the mating interface 160 tofacilitate alignment and fastening at the bolt holes 400, 405 (see FIGS.5 and 8 ).

FIG. 10 is a flow chart illustrating a method 1000 of aligning andfastening together two launch vehicle portions (e.g., the launch vehicleportions 100, 130 described above). Beginning at block 1010, operatorscoarsely adjust the launch vehicle portions 100, 130, for example, usingthe movable platform 120 described above. The portions 100, 130 can bebrought together to be approximately flush at the mating interface 160(see FIG. 4 , for example). In block 1020, operators may optionallyinstall the bushings 440 in the bolt holes 400, 405 of the portions 100,130 (see FIG. 4 ). In block 1030, operators can position the pegs 520,550 in the bolt holes 400, 405 and/or in the bushings 440, and theoperators can position the actuation nub 565 in the socket 570 (see FIG.5 ). In block 1040, operators can engage the locking mechanisms 515, 545of the alignment tool 500 to fix the alignment tool 500 to the launchvehicle portions 100, 130. In block 1050, operators can operate themechanism that moves the actuation nub 565 to push or pull on the socket570 and the bolt holes 400, 405, as described above with regard to FIGS.5 and 6 . Optionally, sometime before operating the mechanism to movethe actuation nub 565, additional alignment tools 500 may be positionedon the launch vehicle portions 100, 130 and one or more bracing beams800, 810 may be positioned to connect multiple alignment tools 500.

In block 1060, operators can check the alignment of the bolt holes 400,405, for example, using GO/NO-GO gauges or by attempting to fit thefasteners in the bolt holes 400, 405. In some embodiments, alignmentdoes not necessarily mean perfect alignment, rather, alignment includesalignment of the bolt holes 400, 405 that is sufficient for a fastenerto fit in both bolt holes 400, 405 at the same time. If the alignment issufficient, in block 1070, operators can install the fasteners in theopen bolt holes 400, 405. When several fasteners are installed (forexample, filling most or all of the bolt holes 400, 405 that do not havepegs 520, 550), at block 1080, the alignment tool 500 can be removed(including the bushings 440, if any). In block 1090, the remainingfasteners can be installed in the open bolt holes 400, 405. Optionally,in block 1030, the method can further include connecting adjacentalignment tools 500 using one or more bracing beams 800, 810 (see FIGS.8 and 9 ).

One feature of several of the embodiments described above with regard toFIGS. 1-10 , and with other embodiments configured according to thepresent disclosure, is an improved mating process for the launch vehicleportions, achieved by aligning bolt holes (and/or other fasteningfeatures) and/or maintaining or restoring the cross-sectional shape ofthe launch vehicle portions before and/or during the mating orintegration process. Alignment tools and associated equipment configuredin accordance with embodiments of the present technology may have arelatively light weight (e.g., 40 pounds) and/or a sufficiently smallsize to facilitate use and manipulation by one or more humantechnicians, without the assistance of a robot or other mechanicalassistance. For example, a technician can apply torque to the inputshaft 595 with a standard hand tool. In some embodiments, however, arobot can move and/or operate the tools and associated equipment.

From the foregoing, it will be appreciated that specific embodiments ofthe disclosed technology have been described herein for purposes ofillustration, but that various modifications may be made withoutdeviating from the technology. For example, where a hand tool or manualdevice causes motion or force, in some embodiments, a machine and/ormotor may be used to provide the motion or force. Accordingly, theprocesses described herein can be performed manually and/or by a roboticdevice.

In further embodiments, one or both of the locking mechanisms 515, 545can be omitted and an alignment tool 500 can connect to a launch vehicleportion 100, 130 using only a peg 520, 550. The bathtub regions 420 canhave any suitable shape, and the tooling disclosed herein can bemodified to be received in differently-shaped bathtub regions 420.Further embodiments of the present technology can adjust bolt holes thatare not oriented parallel to the launch vehicle portion. Steps of themethod 1000 described above with regard to FIG. 10 may be performed in adifferent order, and some steps may be omitted. Although specificdimensions have been provided for context and/or to indicaterepresentative embodiments, various further embodiments can have othersizes.

Although embodiments of the present technology are disclosed herein inconnection with rockets and launch vehicle portions, embodiments of thepresent technology can be implemented in connecting other structures,including horizontally-oriented non-circular structures, verticalstructures, or generally in other circumstances in which tubes, pipes,or hollow sections (which may not necessarily be launch vehicleportions) are to be joined. In some embodiments, the technology canfacilitate alignment of welding locations or other attachment locations,for example, by using attachment points to receive the pegs 520, 550instead of, or in addition to, fastener holes 400. Accordingly,embodiments of the present technology may be used to align structuresthat are connected together with fastening methods other than bolts.

Certain aspects of the technology described in the context of particularembodiments may be combined or eliminated in other embodiments. Further,while advantages associated with certain embodiments of the disclosedtechnology have been described in the context of those embodiments,other embodiments may also exhibit such advantages, and not allembodiments need necessarily exhibit such advantages to fall within thescope of the present technology. Accordingly, the present disclosure andassociated technology can encompass other embodiments not expresslyshown or described herein.

As used herein, the term “and/or” when used in the phrase “A and/or B”means “A, or B, or both A and B.” A similar manner of interpretationapplies to the term “and/or” when used in a list of more than two terms.

I claim:
 1. An aerospace system comprising an alignment tool configuredto align a first fastener hole in a first launch vehicle portion with asecond fastener hole in a second launch vehicle portion, wherein thealignment tool comprises: (a) a receiver assembly comprising a firstlocking mechanism and a first peg, the first locking mechanism and thefirst peg configured to connect the receiver assembly to the firstlaunch vehicle portion, wherein the first peg is positionable in thefirst fastener hole and the first locking mechanism comprises a firstmovable shoe positionable to press against the first launch vehicleportion; and (b) an actuation assembly comprising a second lockingmechanism and a second peg, the second locking mechanism and the secondpeg configured to connect the actuation assembly to the second launchvehicle portion, wherein the second peg is positionable in the secondfastener hole and the second locking mechanism comprises a secondmovable shoe positionable to press against the second launch vehicleportion; wherein: the actuation assembly is separate from, andconnectable to, the receiver assembly at a force interface between theactuation assembly and the receiver assembly; and when the receiverassembly is connected to the first launch vehicle portion, when theactuation assembly is connected to the second launch vehicle portion,and when the actuation assembly is engaged with the receiver assembly atthe force interface, the actuation assembly is operable to applyopposing forces to the receiver assembly and the second launch vehicleportion.
 2. The aerospace system of claim 1, wherein the force interfacecomprises a first connecting element carried by the receiver assemblyand a second connecting element carried by the actuation assembly,wherein the first and second connecting elements are positionable toengage each other to transfer force between the receiver assembly andthe actuation assembly.
 3. The aerospace system of claim 2, wherein thefirst connecting element comprises one of a nub or a socket, and whereinthe second connecting element comprises the other of a nub or a socket,and wherein the force interface comprises the actuation nub inengagement with the socket.
 4. The aerospace system of claim 3, whereinthe socket is formed as an opening between two shear pins.
 5. Theaerospace system of claim 2, wherein the actuation assembly comprises achassis and the first connecting element is movable relative to thechassis via a mechanism carried by the chassis.
 6. The aerospace systemof claim 5, wherein the mechanism comprises a threaded shaft that isrotatable relative to the chassis and an actuation block positioned tomove along the threaded shaft when the threaded shaft is rotated,wherein the actuation block carries the second connecting element, andwherein when the actuation block moves along the threaded shaft, thesecond connecting element applies force to the first connecting element.7. The aerospace system of claim 6, further comprising an input shaftconnected to the threaded shaft to provide torque to the threaded shaft,wherein the input shaft is configured to engage a hand tool for a userto apply torque to the threaded shaft.
 8. The aerospace system of claim7, wherein the input shaft is connected to the threaded shaft via atorque limiting coupler.
 9. The aerospace system of claim 1, wherein thefirst locking mechanism comprises a pushing rod connected to the firstmovable shoe, and wherein the first locking mechanism further comprisesa pushing device positioned to move the pushing rod.
 10. The aerospacesystem of claim 9, wherein the pushing device comprises a lever.
 11. Theaerospace system of claim 10, further comprising a bushing positionablewithin one of the fastener holes and configured to receive one of thepegs.
 12. The aerospace system of claim 1, further comprising the firstlaunch vehicle portion and the second launch vehicle portion.
 13. Theaerospace system of claim 12, wherein the first launch vehicle portionor the second launch vehicle portion comprises a radially-inwarddepression forming an open space for receiving the first movable shoe orthe second movable shoe, and wherein the corresponding first fastenerhole or second fastener hole is positioned in a flange extendingradially outwardly from the depression.
 14. The aerospace system ofclaim 1, wherein the alignment tool is a first alignment tool, thesystem further comprising a second alignment tool configured to align athird fastener hole in the first launch vehicle portion with a fourthfastener hole in the second launch vehicle portion.
 15. The aerospacesystem of claim 14, further comprising a bracing beam for connecting thefirst alignment tool to the second alignment tool.
 16. The aerospacesystem of claim 15, wherein the bracing beam is a first bracing beam,the system further comprising a second bracing beam, wherein the firstbracing beam is configured to connect the actuation assembly of thefirst alignment tool to an actuation assembly of the second alignmenttool, and wherein the second bracing beam is configured to connect thereceiver assembly of the first alignment tool to a receiver assembly ofthe second alignment tool.
 17. The aerospace system of claim 1, whereinthe force interface comprises a first connecting element carried by thereceiver assembly and a second connecting element carried by theactuation assembly, wherein the first connecting element is positionablein the second connecting element or the second connecting element ispositionable in the first connecting element.
 18. A system for aligningfirst fastener holes in a first tubular structure with second fastenerholes in a second tubular structure, the system comprising an alignmenttool, the alignment tool comprising: a receiver assembly comprising afirst chassis, a first peg attached to the first chassis and configuredto be positioned in one of the first fastener holes, and a firstconnecting element attached to the first chassis; and an actuationassembly comprising a second chassis, a second peg attached to thesecond chassis and configured to be positioned in one of the secondfastener holes, and a second connecting element movably attached to thesecond chassis; wherein: (a) the first connecting element and the secondconnecting element are positioned and configured to engage one another,wherein the first connecting element is positionable in the secondconnecting element, or the second connecting element is positionable inthe first connecting element; and (b) when the first connecting elementis engaged with the second connecting element and the second connectingelement is moved relative to the second chassis, the actuation assemblyapplies force to the receiver assembly.
 19. The system of claim 18,wherein one of the first connecting element or the second connectingelement comprises a nub, and wherein the other of the first connectingelement or the second connecting element comprises a socket configuredto receive the nub.
 20. The system of claim 18, wherein: the actuationassembly comprises a threaded shaft rotatably attached to the secondchassis; the second connecting element is movably attached to the secondchassis via the threaded shaft; and wherein rotation of the threadedshaft causes the second connecting element to move along the threadedshaft.
 21. The system of claim 18, wherein the receiver assemblycomprises a first locking mechanism attached to the first chassis andconfigured to press against the first tubular structure, and wherein theactuation assembly comprises a second locking mechanism attached to thesecond chassis and configured to press against the second tubularstructure.
 22. The system of claim 21, wherein the first lockingmechanism or the second locking mechanism comprises a movable shoepositionable to press against the first or second tubular structure. 23.The system of claim 18, further comprising a bushing positionable withinone of the fastener holes and configured to receive one of the pegs. 24.The system of claim 18, wherein the alignment tool is a first alignmenttool, the receiver assembly is a first receiver assembly, and theactuation assembly is a first actuation assembly, the system furthercomprising: a second alignment tool having a second receiver assemblyand a second actuation assembly; a first bracing beam for connecting thefirst receiver assembly to the second receiver assembly; and a secondbracing beam for connecting the first actuation assembly to the secondactuation assembly.
 25. The system of claim 18, wherein the alignmenttool is a first alignment tool and the system further comprises: asecond alignment tool; and a bracing beam for connecting the firstalignment tool to the second alignment tool.
 26. The system of claim 18,wherein the actuation assembly is separate from, and connectable to, thereceiver assembly via the engagement between the first connectingelement and the second connecting element.